C5-SYNERGIE
The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer. The technical information appearing in this brochure is subject to updating as the characteristics of each model in the range evolve. Motor vehicle repairers are invited to contact the CITRON network periodically for further information and to obtain any possible updates.
2002
PRESENTATION
THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITROEN vehicles, not including COMMERCIAL vehicles for which there exists a separate handbook. The handbook is divided into nine groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL AIR CONDITIONING. In each section, the vehicles are dealt with in the following order : C5 - SYNERGIE and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.
IMPORTANT
If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : INSUFFICIENT INFORMATION SUPERFLUOUS INFORMATION NEED FOR MORE DETAILS
Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.
IDENTIFICATION OF VEHICLES
(A) Chassis stamp (cold stamp on bodywork). (B) Manufacturers data plate. (under the rear bench seat) GENERAL (C) A-S / RP No. and RP paint code (label on front pillar close to drivers door). (D) Inflation pressures and tyre references. (label on front pillar close to drivers door) (E) Serial no. on bodywork. (F) Gearbox reference Factory serial no. (G) Engine legislation type Factory serial no
E1APO8RD
C5 - All Types
IDENTIFICATION OF VEHICLES
Petrol saloons 1.8i 16V Automatic X-SX 2.0i 16V Automatic X-SX-Exclusive L4 DC 6FZE L5 DC RFNC/IF L4 DC RFNB RFN 1997 8 AL4 20 TP 44 BE4/5 20 BL 30 9 AL4 20 TP 42 L5 DC RFNE
Emission standard
L4 DC 6FZB
GENERAL
Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate
IDENTIFICATION OF VEHICLES
Petrol saloons 2.0 HPi 30.i 24V V6
C5 - All Types
Automatic Exclusive
Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate
C5 - All Types
IDENTIFICATION OF VEHICLES
Diesel saloons 2.0 HDi Automatic X X-Exclusive L4 DC RHYB RHY 6 BE4/5 20 DL 32 ML/5C 20 LM 18 ML/5T (*) 20 LE 94 DC RHSB RHS 1997 7 AL4 20 TP 43 ML/5C 20 LM 18 6 ML/5T 20 LE 94 7 AL4 20 TP 43 DC RHSE DC RHZB RHZ DC RHZE Automatic
Emission standard
GENERAL
Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate
IDENTIFICATION OF VEHICLES
Diesel saloons 2.2 HDi
C5 - All Types
Automatic SX-Exclusive
Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp)
Gearbox type
Gearbox ident. plate
C5 - All Types
IDENTIFICATION OF VEHICLES
Petrol estates 1.8i 16V 2.0i 16V Automatic X-SX SX Exclusive
L5 DE 6FZB 6FZ 1749 7 BE4/5 20 DL 29 20 DL 30 9 AL4 ? DE RFNC/IF RFN 1997 8 BE4/5 20 DL 31 ML/5C 20 LM 21 13 ML/5T 20 LE 95 DE RFNE L4 DE RLZB RLZ DE XFX/IF XFX 2946 14 4 HP 20 20 HZ 13
2.0 HPi
GENERAL
Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate
L4 DE 6FZC/IF
IDENTIFICATION OF VEHICLES
Diesel estates 2.0 HDi Automatic X
Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate
C5 - All Types
Automatic
X-Exclusive L4 GENERAL
DE RHSB RHS
DE RHZE
7 AL4 20 TP 48 (*)
20 LM 18
20 LE 94 (*)
C5 - All Types
IDENTIFICATION OF VEHICLES
Diesel estates 2.2 HDi Automatic SX-Exclusive
Emission standard
GENERAL
Type code Engine type Cubic capacity (cc) Fiscal rating (hp)
Gearbox type
Gearbox ident. plate
IDENTIFICATION OF VEHICLES
1 2 3 4
Manufacturers cold stamp R.P. organisation No. Paint code 01/02/99 # Label : - Tyre pressures. - R.P. Organisation No. - Paint code. Gearbox ident. Engine plate Manufacturers plate GENERAL
5 6 7
E1AP07GD
IDENTIFICATION OF VEHICLES
Petrol 2.0i 16 V Automatic X SX Exclusive GENERAL
Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate IF L5 (*)
X SX
L3
X Taxi SX Exclusive
L4
AF RFNC/IF RFN
AF RFNF/IF
AF RHZA
AF RHWB RHW
10 AL4 20 TP 31
6 ML5 20 LE 91
CAPACITIES
Draining method. The oil capacities are defined according to the following methods. 1) - Vehicle on level surface (in high position, if equipped with hydropneumatic suspension). 2) - Engine warm (oil temperature 80C). 3) - Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 mm). 4) - Refit plug + cartridge. 5) - Engine filling. 6) - Engine starting (allowing the cartridge to be filled). 7) - Engine stopped (stationary for 5 mm).
ALL TYPES
ESSENTIAL : Systematically check the oil level using the oil dipstick.
11
GENERAL
C5 - All Types
Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Braking circuit Hydraulic circuit Cooling system Fuel tank capacity
6FZ
GENERAL
(*) = With automatic gearbox ESSENTIAL : Systematically check the oil level using the oil dipstick 12
C5 - All Types
2.2 HDi Automatic RHZ 4HX GENERAL 4.75 1.5 1.8 1.8 8.3 - 6 (1) 5.3 3 (1) 8.3 5.3 Automatic
RHY
RHS 4.75 1.5 1.8 8.3 - 6 (1) 5.3 3 (1) 4.5 (1) 1.7 (1)
(1) = With air conditioning. ESSENTIAL : Systematically check the oil level using the oil dipstick. 13
Engine type
RFN
RHZ 21
RHW
GENERAL
Engine angle Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Hydraulic or brake circuit Cooling system Fuel tank capacity
4.75 1.9
Without ABS : 0.47 - With ABS : 0.52 7 80 - ESSENTIAL : Systematically check the oil level using the oil dipstick. 14 8.5 80
ALL TYPES
E4AP006D
15
GENERAL
ALL TYPES
Factory evolutions in 2001 model year
CITRON engines are lubricated at the factory with TOTAL oil of grade S.A.E.5W-30. TOTAL oil of grade S.A.E.5W-30 allows improved fuel economies (approx 2.5%). Features of CITRON C5 : 2.0 and 2.2 HDi engines have a particle filter. The maintenance interval for normal operation is 30,000 km (20,000 miles) for petrol engines. WARNING : HDi engines are high technology engines which imperatively require use of quality SYNTHETIC OILS : TOTAL ACTIVA or TOTAL QUARTZ 5W40. To maintain engine performances, all countries in Europe should observe this requirement. NOTE : Only PORTUGAL and GREECE may use 10W40 semisynthetic oil. GENERAL
16
ALL TYPES
ACEA Norms The first letter corresponds to the type of engine concerned : A : petrol and dual fuel petrol / LPG engines. B : diesel engines. The figure following the first letter corresponds to the type of oil. 1 : highly fluid oils, for reducing friction and lowering fuel consumption. 3 : high performance oils. The number after that (96 or 98) corresponds to the year of creation of the norm. NOTE : From 01/03/2000, all engine oils must comply with ACEA98 norms. Example : ACEA A1-98 / B1-98 : Blended oils for all engines, permetting fuel economy (complying with ACEA 98 norms).
API Norms The first letter corresponds to the type of fuel used by the engine : S : petrol and dual fuel petrol / LPG engines. C : diesel engines. The second letter corresponds to the degree of evolution, in ascending order. Example : The norm SJ is more severe than the norm SH and corresponds to a higher level of performance. The adding of the letters EC indicates that the engine oil concerned is an oil which permits fuel economy. EC : Energy Conserving, reduction in fuel consumption. Examples : API SJ / CF : Blended oils for diesel and dual fuel petrol / LPG engines API CF / EC : Oils specifically for diesel engines, permitting fuel economy. API SJ / CF / EC : Blended oils for all engines, permetting fuel economy. 17 GENERAL
ALL TYPES
Engine oil norms. Norms in force. These engine oils have been classified by the following recognised organisations: S.A.E. : Society of Automotive Engineers. API : American Petroleum Institute. ACEA : Association des Constructeurs Europens dAutomobiles. Recommendations. Denominations of TOTAL oils, according to country of marketing: TOTAL ACTIVA (France only). TOTAL QUARTZ (Outside France). ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic) Summary Engine oil norms to be respected in 2001 model year. Model year AM 2001 Types of engine Petrol and dual fuel petrol / LPG engines Diesel engines ACEA norms A3-98 or A1-98 (*) B3-98 or B1-98 (*) API norms SJ or SJ / EC (*) CF or CF / EC (*)
GENERAL
(*) = It is essential not to use engine oils respecting these norms for the following engine-types . XU10J4RS. 1580 SPI. SOFIM 2.8 D et SOFIM 2.8 TD. 18
ALL TYPES
ACEA norms
Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 TOTAL QUARTZ 9000 TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000 TOTAL ACTIVA DIESEL 7000 TOTAL ACTIVA DIESEL 9000 19 10W-40 0W-40 15W-50 Oils specifically for diesel engines 10W-40 15W-50 5W-40 CF B3-98 SJ A3-98
ALL TYPES
Metropolitan FRANCE
S.A.E : 10W-40 Norms TOTAL ACTIVA DIESEL Oils specifically for diesel engines 7000 10 W-40 9000 5W-40
Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10 W-40
GENERAL
Metropolitan FRANCE New Caledonia Guadeloupe Saint-Martin La Runion Martinique Guyana Tahiti Mauritius Mayotte
9000 5W-40
7000 15W-50
7000 15W-50
(*) = HDi FAP (Particle filter) - (**) = Blended oils for all engines, permitting fuel economy. 20
ALL TYPES
TOTAL QUARTZ DIESEL Oils specifically for diesel engines
7000 10W-40
GENERAL
ALL TYPES
(*) = Blended oils for all engines, permitting fuel economy Greece Holland Hungary Italy Ireland Iceland Latvia Lithuania Macedonia Malta Moldova Norway Poland Portugal Slovak Republic GENERAL
Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 7000 7000 9000 10W-40 15W-50 10W-40 0W-40
7000 10W-40 9000 5W-40 9000 5W-30 (*) 7000 9000 7000 7000 7000 7000 7000 9000 10W-40 0W-40 10W-40 10W-40 15W-50 10W-40 10W-40 0W-40
7000 10W-40
7000 10W-40 22
ALL TYPES
TOTAL QUARTZ DIESEL Oils specifically for diesel engines
Czech Republic Romania Russia Slovenia Sweden Switzerland Turkey Ukraine Yugoslavia 23 9000 5W-40 9000 5W-30 (*)
7000 10W-40 9000 0W-40 7000 10W-40 7000 10W-40 9000 0W-40 7000 10W-40 7000 10W-40 7000 15W-50 9000 0W-40 7000 10W-40 9000 0W-40 7000 10W-40 7000 10W-40
GENERAL
ALL TYPES
Australia New-Zealand Ivory Coast Egypt Gabon Madagascar Morocco Senegal Tunisia Argentina Brazil, Chile Cuba Mexico Paraguay Uruguay GENERAL
OCEANIA
24
ALL TYPES
TOTAL QUARTZ DIESEL Oils specifically for diesel engines
7000 15W-50 9000 5W-40 7000 10W-40 7000 15W-50 7000 15W-50
GENERAL
7000 10W-40
ALL TYPES
Saudi Arabia Bahrain Dubai United Arab Emirates Iran Israel Jordan Kuwait Lebanon Oman Qatar Yemen 26 MIDDLE EAST 9000 5W-40 7000 15W-50 7000 10W-50 GENERAL
ALL TYPES
TOTAL TRANSMISSION BV Norms S.A.E 75W-80 Special oil distributed by CITRON (Part No. 9730 A2) TOTAL FLUIDE ATX or TOTAL FLUIDE AT 42. Special oil distributed by CITRON (Part No. 9730 A3). Special oil distributed by CITRON (Part No. 9736 22). TOATAL TRANSMISSION X 4
Manual gearbox
Power steering oils All countries Power- assisted steering Very cold countries TOTAL FLUIDE ATX TOTAL FLUIDE DA Special oil distributed by CITRON (Part No. 9730 A1)
27
GENERAL
All countries
ALL TYPES
All countries
Protection : - 35C
GENERAL All countries CITROEN Fluid All countries TOTAL LHM PLUS TOTAL FLUIDE LDS
1 litre 5litres CITROEN hydraulic circuit fluid Norm ISO 7308-7309 Green in colour Orange in colour 28 Pack 1 litre
ALL TYPES
9980 56
ZC 9875 279 U
GENERAL
ALL TYPES
I - Oil consumption depends on : - the engine type. - how run-in or worn it is. - the type of oil used. - the driving conditions. II - An engine can be considered RUN-IN after: GENERAL - 3,000 miles (5,000 km) for a PETROL engine. - 6,000 miles (10,000 km) for a DIESEL engine.
III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine. - 0.5 litres per 600 miles (1,000 km) for a PETROL engine - 1 litre per 600 miles (1,000 km) for a DIESEL engine. DO NOT WORK BELOW THESE VALUES. IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil. - This excess oil will be used up rapidly. - It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.
30
ENGINE SPECIFICATIONS
Engines : 6FZ - RFN - RLZ - XFX Petrol
ALL TYPES
1.8i 16V
2.0i 16V
2.0 HPi
3.0i-V6
Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC KW - rpm Power DIN (HP - rpm) Torque ISO or EEC (m.daN - rpm)
RLZ
31
ENGINE
ENGINE
ALL TYPES
ENGINE SPECIFICATIONS
Engines : RHS - RHZ - RHY - RHW - 4HX Diesel
2.0 HDi
2.2 HDi
Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC KW - rpm Power DIN (HP - rpm) Torque ISO or EEC (m.daN - rpm)
RHS
RHY
RHW
80-4000 110-4000
32
ALL TYPES
ENGINE
33
ENGINE
ENGINE
Bearing cap screws. - Pre-tightening - Angular tightening Con-rod cap screws. - Tightening - Slackening - Tightening - Angular tightening Con-rod nuts. - Pre-tightening - Angular tightening Accessories drive pulley - Tightening - Angular tightening Accessories drive pulley hub - Pre-tightening - Angular tightening (Sintered washer) - Angular tightening (Steel washer)
2 0.1 60 6
2.5 0.2 60
7 0.25 60
4 0.4 40 4 53 5
34
Piston skirt spray jet Sump - Pre-tightening - Tightening Timing belt guide roller - Pre-tightening - Tightening Timing guide roller - Pre-tightening - Tightening Timing belt tensioner roller RH engine mounting - Pre-tightening - Tightening - Tightening 2.1 0.2 2.5 0.2 3.7 0.3 2.5 0.2 0.8 0.2 1.6 0.2
1 0.1
1 1.6 0.3
2.5 0.2
1 (4 screws) 2 0.2 ( 8) 4.50.2 (10)
6.1 0.6
2.7 0.2
35
ENGINE
ENGINE
Valve cover - Pre-tightening - Tightening Hub pulley Flywheel - Pre-tightening - Tightening Clutch plate
Camshaft bearing cover - Tightening - Pre-tightening - Tightening Exhaust manifold - Pre-tightening - Tightening
1 0.1
2 0.2
0.9 0.1
36
0.9 0.1
1.3 0.1 5.8 0.5 3 0.3 2 0.2 (Flange nut) 3 0.3 2 0.2 2.25 0.3 2 0.2 5 0.5 2 .02
0.4 0.03 45 5
0.5 0.1 0.9 0.1 0.8 0.1 2.6 0.3 1.4 0.1 0.9 0.1
37
ENGINE
ENGINE
C5 - All Types
CYLINDER HEAD
Engines : 6FZ - RFN - RLZ Cylinder head gasket identification
Nominal dimension 6FZ Marking zone "d" Marking zone "e" Gasket thickness (mm) Supplier 0.8 MEILLOR 4-5 RFN - RLZ 1-4
Repair dimension
2-4-5 R1 R2
1.1
1.4
38
CYLINDER HEAD
Engines : 6FZ - RFN - RLZ Cylinder head tightening (m.daN) 6FZ - RFN - RLZ Pre-tightening Tightening Slackening Tightening Angular tightening 1.5 0.1 5 0.1 360 2 2 0.2 285 5 Cylinder head bolts
B1DP16FC
NOTE : Retightening of the cylinder head after a completed repair is prohibited.Intervention est interdit.
B1DP05BC
NOTE: Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus.)
A = Washer thickness : 4 0.2 mm. X = Length under heads of the new bolts = 144.5 0.5 mm. X = MAX. re-usable length 6FZ - RFN - RLZ X= 147 mm
39
ENGINE
ENGINE
B1BP1HAP
(1) Compact coil unit (9) Flywheel - Tightening - Angular tightening (11) Connecting rod caps - Tightening - Angular tightening (12) Crankshaft hub - Tightening - Angular tightening (13) Crankshaft pulley
1 0.1
1 60 6
2 74 7
40
B1DP08UD
B1DP08TD
WARNING : Tighten screw by screw in the order shown. - Pre-tighten : - Tighten : 0.5 1 0.1 41 - Pre-tighten : - Tighten : 0.2 0.8
ENGINE
ENGINE
B1HPOLJC
B1DP097C
WARNING : Tighten screw by screw in the order shown. - Pre-tighten : - Tighten : 1 0.1 2 0.2 42 - Pre-tighten : - Tighten : 1 0.1 2.5 0.2
B1BP1GXD
B1BP1GZD
WARNING : Tighten screw by screw in the order shown. - Pre-tighten : - Tighten : 1 0.1 3 0.3 43 - Pre-tighten : - Tighten : 0.5 0.8
ENGINE
ENGINE
B1BP1GYD
- Clean the threads of the screws with a brush. - Refit the screws with a coating of grease ( MOLYKOTE G RAPID PLUS ). - Check that the 8 centring pins are in place. Maximum length under the heads of the screws : - M11 = 131.5 mm. - M8 = 119 mm. - Pre-tighten the M11 screws to 3 m.daN 0.3 (1 to 8 ). - Pre-tighten the M8 screws to 1 m.daN 0.1 (A to H). - Tighten the M6 screws to 1 m.daN 0.1 (a to m). - Slacken the M11 and M8 screws (screw by screw). - Tighten the M11 screws to 3 m.daN 0.3 (1 to 8). - Tighten the M8 screws to 1 m.daN 0.1 (A to H).
44
(14) Water pump - Pre-tighten - Tighten (15) Oil pump - Pre-tighten - Tighten (16) Guide roller (17) Tensioner roller (18) Camshaft hubs - Pre-tighten - Tighten (19) Camshaft pulley
B1BP1HBD
0.5 0.8
2 0.2 57 5 1 0.1
45
ENGINE
ENGINE
B1BP1H1D
WARNING : Tighten screw by screw in the order shown. - Pre-tighten - Tighten 0.5 1 0.1
46
CYLINDER HEAD
Engine : XFZ Cylinder head gasket identification Supplier Thickness (Standard) (mm) 0.75 Thickness reference Central lug Exhaust end
ERLING
B1DP18YD
ENGINE
ENGINE
CYLINDER HEAD
Engine : XFX Cylinder head tightening (m.daN) Cylinder head bolts
In the order indicated. - Pre-tightening - Slackening - Pre-tightening - Angular tightening 2 0.2 YES 1.5 0.2 225
Note : Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus). X = MAX. re-usable length XFX
B1DP18ZD B1DP09VC
149.5 mm
48
CYLINDER HEAD
Engines : RHY - RHS - RHZ Cylinder head gasket identification Engine plate Piston stand-proud (mm) 0.47 to 0.605 RHZ RHY 0.605 to 0.655 0.655 to 0.705 0.705 to 0.755 0.755 to 0.83 Thickness (mm) 1.30 0.06 1.35 0.06 1.40 0.06 1.45 0.06 1.50 0.06 Number of notches at A 1 2 3 4 5
B1DP15AD
49
ENGINE
ENGINE
B1DP05BC
CYLINDER HEAD
Engines : RHY - RHS - RHZ Cylinder head gasket identification Cylinder head tightening (m.daN) RHY - RHS - RHZ - Pre-tightening - Tightening - Angular tightening 2 6 220 Cylinder head bolts RHY - RHS - RHZ
NOTE : Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus). X = MAX. re-usable length RHY - RHS - RHZ 133.3 mm 50
B1DP15EC
CYLINDER HEAD
Engine : 4HX Cylinder head gasket identification Number of notches Engine plate Piston stand-proud (mm) 0.55 to 0.60 4HX 0.61 to 0.65 0.66 to 0.70 0.71 to 0.75 Thickness (mm) 1.25 0.04 1.30 0.04 1.35 0.04 1.40 0.04 1
At A
At B 1 2 3 4
Cylinder head gasket. Multilayer cylinder head gasket. Select seal thickness as a function of the piston stand-proud.
B1DP18XD
51
ENGINE
ENGINE
B1DP05BC
- Pre-tightening - Tightening - Slackening - Pre-tightening - Tightening - Angular tightening (in 2 attempts max.)
2 0.2 (Order 6 0.6 (Order 360 (Order 2 0.2 (Order 6 0.6 (Order 220 5 (Order
1 to 10) 1 to 10) 10 to 1) 1 to10) 1 to10) 1 to10) NOTE : Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus). X = MAX. re-usable length 4HX X = 134.5 MM
B1DP15EC
52
B1EP135D
53
Tooling
ENGINE
ENGINE
C5 - SYNERGIE
EW 7 J4 Engine type C5 SYNERGIE See pages : 6FZ X RFN X X 56 10 D RLZ X
54
ALL TYPES
TOOLS - Belt tension measuring instrument : 4122 - T. (C.TRONIC 105.5) - WARNING : If using tool 4099-T (C.TRONIC 105) refer to the correspondence table on page 53.
ESSENTIAL - Before refitting the auxiliary equipment drive belt, check that : 1) The roller(s) rotate freely (no play or stiffness) 2) The belt is correctly engaged in the grooves of the various pulleys.
55
ENGINE
ENGINE
SYNERGIE
Without aircon
With aircon
7504-T
56
C5 - All Types
Remove. Remove the engine cover. Pivot the tensioner roller bracket (1) clockwise, until it locks, using tools [1] and [2] at a. Remove the auxiliary equipment drive belt. ESSENTIAL : Check that the guide rollers are turning freely. (No play and no tightness). Refit. Refit the auxiliary equipment drive belt: Respect the following order of assembly : - The crankshaft pulley (2). - The tensioner roller (3). Release the tensioner roller bracket (1), by turning it anti-clockwise, using tools [1] and [2]. ESSENTIAL : Make sure that the belt is correctly positioned in the grooves of the various pulleys. 57
B1BP27EC
B1BP27FC
ENGINE
ENGINE
SYNERGIE
Remove Re-use of belt WARNING : Mark the direction the belt was fitted in case of re-use of the same belt. - Compress the tensioner roller (2) by action at a (in anti-clockwise direction), tool [4]. - Keep the tensioner roller (2) compressed and remove the belt. No re-use of belt. - Compress the dynamic tensioner roller (2) by action at a (anti-clockwise), using tool [4]. - Peg using tool [2], at b . - Hold the dynamic tensioner roller (2) compressed and remove the belt. - Loosen the screw (1).
B1BP1YKD
58
SYNERGIE
- Compress the tensioner roller (2) by action at a (anti-clockwise), tool [4]. - Refit the belt. WARNING : Respect the direction in which the belt is fitted. - Remove the tool [4]. New belt. Refit the belt. - Turn the eccentric roller (3), tool [1] (clockwise) to free the tool [2] from its pegging at b . - Hold the eccentric roller (3), tool [1], and tighten the screw (1) to 4.3 0.5 m.daN. Remove the tool [2]. - Rotate the crankshaft 4 times in the direction of rotation. - Check that it is possible to peg at b , tool [3]. - If not possible to peg, restart the adjustment.
B1BP1YMD
59
ENGINE
ENGINE
SYNERGIE
Remove Re-use of belt WARNING : Mark the direction the belt was fitted in case of re-use of the same belt. - Compress the tensioner roller (7) by moving it at c (in anti-clockwise direction), tool [4]. - Hold the tensioner roller (7) compressed and remove the belt. No re-use of belt. - Compress the tensioner roller (7) by moving it at c (in anti-clockwise direction), tool [4]. - Peg using tool [2], at d . - Loosen the screw (6). - Bring the eccentric roller (5) towards the rear. - Tighten the screw (6) by hand. - Remove the belt.
B1BP1YLD
60
SYNERGIE
Re-used belt. - Compress the tensioner roller (7) by action at c (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the direction in which the belt is fitted. - Remove the tool [4]. New belt. Refit the belt. - Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its pegging at d . - Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 0.5 m.daN. - Remove the tool [2]. - Rotate the crankshaft 4 times in the normal direction of rotation. - Check that it is possible to peg at d , tool [3]. - If not possible to peg, restart the adjustment.
B1BP1YND
61
ENGINE
ENGINE
C5 - All Types
B1BP270D
B1BP272D
62
C5 - All Types
: (-).0188.Z : (-).0188.Q1
- Compress the tensioner roller (4) by action at c (anti-clockwise), using tool [1]. - Peg at d, using tool [2]. - Remove the auxiliaries drive belt. Refit. - Refit the auxiliaries drive belt. - Compress the tensioner roller (4) by action at c (anti-clockwise), using tool [1]. - Remove the tool [2] at d.
B1BP271D
B1BP273D
63
ENGINE
ENGINE
C5 - All Types
EW 7 J4 Engine type C5 SYNERGIE See pages : 6FZ X RFN X X 65 to 68 10
64
C5 - All Types
ENGINE
ENGINE
C5 - All Types
66
C5 - All Types
IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15 below the level of the cylinder head gasket g. If not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6). Refit (continued). - Remove the tools [1] and [2]. -Turn the crankshaft 10 times in the normal direction of rotation. IMPERATIVE : No pressure or outside action must be brought to bear on the timing belt. - Peg the inlet camshaft pulley, using the tool [1]. Checks. Timing belt tension. IMPERATIVE : Check the position of the index c, it should be facing the notch f. If the position of index c is not correct, restart the adjustment of its position. Positioning of the crankshaft. - Fit tool [2]. - As long as it is possible to fit tool [2], continue with the refit operations. IMPERATIVE : If it is not possible to fit tool [2], reposition the flange (14).
B1EP14MC B1EP14VC
67
ENGINE
ENGINE
C5 - All Types
68
C5 - All Types
Remove the auxiliaries drive belt (See corresponding operation). Checking the valve timing setting. Remove : - The power steering pulley. - The roller / dynamic tensioner assembly (11). - The crankshaft pulley (12). - The upper timing covers (9) and (10). - The lower timing cover (13).
B1BP2BKC
69
ENGINE
ENGINE
C5 - All Types
Refit : - The - The - The - The - The lower timing cover (13). upper timing covers (9) and (10). crankshaft pulley (12). roller / dynamic tensioner assembly (11). power steering pulley.
B1EP08TC
B1EP15UD
70
C5 - All Types
NOTE : Damp the rotation of the camshafts (15) and (17), using tool [6]. - Untighten the camshaft pulley screws (15) and (17). NOTE : Damp the rotation of the camshafts (14) and (18), using tool [5]. - Untighten the camshaft pulley screws (14) and (18). NOTE : Lubricate the tools [1], with grease G6 (TOTAL MULTIS). Peg the camshafts, using tools [1], [5] and [6]. Remove the screw (21) of the panel (25). Untighten the nut (23) of the tensioner roller (24). Untighten the screws (22) of the panel (25). Remove the guide roller (16). WARNING : mark the direction of fitting of the timing belt, in case the belt is to be reused - Remove the timing belt.
B1EP15VD
71
ENGINE
ENGINE
C5 - All Types
B1BP2BLC
72
C5 - All Types
- Pivot the plate (25) of the tensioner roller (24), using a spanner. (type FACOM S.161). - Engage the screw (21) on the plate (25). - Tighten the screws (21) and (22), tighten to 2,5 0,1 m.daN. - Position the belt under maximum tension ; pivot the tensioner roller (24),using a spanner (type FACOM R 161). - Tighten the nut (23) of the tensioner roller (24), tighten to 1 0,1 m.dan. - Check that the camshaft pinion screws are not at the end of slots. (By loosening one screw). - Otherwise, restart the operation of positioning the timing belt. - Tighten at least 2 screws per camshaft pulley to 1 0,1 m.daN. - Remove the tools [1], [2] and [4]. - Rotate the crankshaft 2 turns in a clockwise direction. IMPERATIVE : Never turn it back. - Peg the crankshaft, using tool [2], and the camshaft pulleys, using tool [1]. - Untighten the nut (23) of the tensioner roller (24). - Adjust the belt tension, pivoting the roller (24) using tool (type FACOM S.161).
B1EP15WC B1EP15XC
73
ENGINE
ENGINE
C5 - All Types
B1EP15XC
74
C5 - All Types
75
ENGINE
ENGINE
C5 - All Types
76
C5 - All Types
Reposition the timing belt, keeping the belt tight at a , in the following order : - Guide roller (23). - Fuel high pressure pump pinion (26). - Camshaft pinion (24). - Water pump pinion (18). - Tensioner roller (20). NOTE : If needed, slightly turn the pinion (24) anti-clockwise (not by more than one tooth). - Remove the tool [4].
B1EP153D
B1EP154C
B1EP155D
77
ENGINE
ENGINE
C5 - All Types
B1EP156D
78
C5 - All Types
IMPERATIVE : If value is incorrect, restart the operation. - Remove tools [1], [3] and [5]. - Rotate the crankshaft 2 times (normal direction of rotation). - Fit the tool [3]. WARNING : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. In the case of an incorrect value, recommence the operation. - Remove the tool [3]. - Complete the refitting of components.
B1EP156D
79
ENGINE
ENGINE
C5 - All Types
IMPERATIVE : Respect the safety and cleanliness recommendations specific to high pressure diesel injection (HDi) engines. Checking the setting of the valve timing. - Turn the crankshaft (normal direction of rotation) and line up the black markings on the chain (b) and (c) with the teeth marked (a) and (d) of the camshaft drive pinions (40 turns max. of the camshaft).
B1EP159D
80
C5 - All Types
IMPERATIVE : If it is impossible to line up the marks on the chain and on the camshaft drive pinions, restart the camshaft setting. (See operation for removing and refitting camshafts). - If the marks on the chains and pinions are coinciding, continue the checking operations. Peg : - The crankshaft, using tool [2]. - The camshaft pinion, using tool [5]. IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm (use a screw 7 mm in dia.). If the offset is more than 1 mm, restart the setting of the valve timing (See corresponding operation). - Remove the tools [2] and [5].
B1BP298C B1EP15AD
81
ENGINE
ENGINE
C5 - All Types
82
C5 - All Types
B1EP15BD B1EP15CC
B1EP15DD
83
ENGINE
ENGINE
C5 - All Types
B1EP15ED
84
C5 - All Types
- Remove tools [1], [2] and [5]. - Rotate the crankshaft 2 times (normal direction of rotation). - Fit the tool [3]. IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. In the case of an incorrect value, recommence the operation. - Remove the tool [2]. - Complete the refitting of components.
B1EP15ED
85
ENGINE
ENGINE
ALL TYPES
The valve clearances must be checked with the engine cold G Inlet Exhaust
VALVE CLEARANCES
POSSIBLE PROCEDURES For engines with 4 cylinders in a line (1-3-4-2 ) Rocking Rocking Adjust 4 2 1 3 G Exhaust Inlet Fully open (Exhaust) Valves fully Adjust open
1 3 4 2 3 G 4 G 2 G 1 G 4 2 1 3
All Types
Hydraulic adjustment
1G 3G 4G 2G
1 4G 3 2G 4 1G 2 3G
Engines without hydraulic adjustment : the clearance (J) should be checked opposite the cam.
B1DP13QC
86
C5 - All Types
3.0i V6 XFX
8 3000
Diesel engines 2.0 HDi Engine type Temperature (C) Pressure (Bars) Rpm 2 1000 4 2000 2 1000 RHY - RHS -RHZ 90 4 2000 2 1000 4 2000 2.2 HDi 4HX
87
ENGINE
ENGINE
C5 - All Types
OIL FILTERS
To be read together with the petrol and diesel correspondence tables
RFN X
RLZ X
XFX
RHY X
RHS X
RHZ X
4HX X
Height (mm) 89 97
88
C5 - All Types
ESSENTIAL : Respect the safety and cleanliness recommendations. - The draining and refilling operations can be carried out by means of a WINNS coolant replacement apparatus or similar; it is essential to follow the instructions when using this apparatus. Filling and bleeding - Fit the cylinder adaptor [2] 4222-T and the filling cylinder [1] 4520 -T. - Use the coolant to ensure protection between - 15C and - 37C. - Slowly fill the system. NOTE : Keep the cylinder filled up (visible level). - Close each bleed screw as soon as the coolant flows without air bubbles. - Start the engine : Engine speed 1500 rpm. - Maintain this speed until the third cooling cycle (cooling fans have cut in and cut out). - Stop the engine and allow it to cool down. - Remove the filling cylinder [1] 4520-T and the adaptor [2] 4222-T. - Top up the system to the maximum mark, with the engine cold. - Refit the filler cap.
B1GP00AC E5AP1GNC
89
ENGINE
INJECTION
C5 - All Types
Vehicles Engine type Emission standard
IDLING - ANTIPOLLUTION
Make - Injection type Idling speed ( 50 rpm) Manual gearbox Auto. gearbox: N engaged % Content CO CO2
L4 1.8 i 16V 6FZ IF/L5 C5 2.0 i 16V 2.0 HPi 3.0 i V6 SYNERGIE 2.0 i 16V RFN RLZ XFZ RFN IF/L5 L4 IF/L5 IF L5 MAGNETTI MARELLI 48P SIEMENS SIRIUS 81 BOSCH ME 7.4.6. M. MARELLI 48P2 < 0.5 >9 SAGEM S2000 7000
< 0.5
>9
90
PETROL INJECTION
C5 1.8I 16V
Engine type Emission standard Make Injection type Fuel pressure (bars) Overspeed cut-off (rpm) Injection cut-in during deceleration (rpm) Injector resistive value (ohms) Engine coolant temperature sensor resistive value (ohms) Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms)
C5 - All Types
SYNERGIE 2.0 HPi RLZ L4 SIEMENS SIRIUS 81 5 3.0I 24S V6 XFX IF/L5 BOSCH ME 7.4.6. 3.5 6520 1100 2.0 i 16 V RFN IF L5 M. MARELLI 48P2 INJECTION
14.5 2500 at 20 C
16 230 at 90 C
ALL TYPES
INJECTION
# 01/96
Less than 4.5 % for vehicles registered before 10/86. Less than 3.5 % for vehicles registered after 10/86. With catalytic converter Greater than 2.0i 89 M.Y. All Types 93 M.Y. CO less than 0.5 % at idle speed. CO less than 0.3 % at fast idle speed between 2500 and 3000 rpm (*) Lambda Probe value 0.97 to 1.03.
01/96
Atmospheric engine. Less than 2.5 m -1 Turbocharged engine. Less than 3.0 m -1
92
EMISSION STANDARDS
STANDARD E.E.C. PSA A-S RP Engines APPLICATIONS Vehicles Applicable Brussels directive 83/351 except special derogations for certain private vehicles cyl. > 2 litres NOTES
ALL TYPES
CHARACTERISTICS
Private vehicles : > 2 litres new cyl. < 2 litres existing cyl. < 2 litres ECE R 15.04 K K 15.04 15.04 Petrol Diesel Utility vehicles : All Types
ECE R 15.05
W vp
15.05
Petrol
01/10/88 01/10/89
93
INJECTION
ALL TYPES
STANDARD E.E.C. PSA A-S RP Engines
EMISSION STANDARDS
APPLICATIONS Vehicles Applicable Brussels directives 88/76 and 88/436 NOTES CHARACTERISTICS
INJECTION
US 83
US 83
Petrol Diesel
Current
94
EMISSION STANDARDS
STANDARD E.E.C. PSA A-S RP Engines APPLICATIONS Vehicles Private vehicles : certain non-EEC European countries certain Export countries Private vehicles : certain Export countries Utility vehicles : certain non-EEC European countries certain Export countries Utility vehicles : certain non-EEC European countries certain Export countries Applicable NOTES
ALL TYPES
CHARACTERISTICS
US 87
US 87
Diesel
Current
US 93
Y2
US 93
Petrol Diesel
Current
US 84 LDT
X1
US 84
Petrol Diesel
Current
US 87 LDT
X2
US 87
Petrol Diesel
Current
95
INJECTION
ALL TYPES
STANDARD E.E.C. PSA A-S RP Engines Vehicles
EMISSION STANDARDS
APPLICATIONS Applicable NOTES CHARACTERISTICS
US 90 LDT
X3
US 90
Petrol Diesel
Private vehicles : certain non-EEC Current European countries certain Export countries Private vehicles : < 1.4 litres new models existing models
INJECTION
CEE 19.5
Petrol Diesel
Private vehicles : All Types new models existing models new models existing models
With oxygen sensor and catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.
96
EMISSION STANDARDS
STANDARD E.E.C. PSA A-S RP Engines APPLICATIONS Vehicles Utility vehicles : < 3.5 tonnes new models EURO 1 W2 (EURO 93) CEE W2 Petrol Diesel existing models Class 1 : new models existing models Class 2/3 : new models existing models Private vehicles : < 6 seats and < 2.5 tonnes new models existing models Applicable NOTES
ALL TYPES
CHARACTERISTICS
01/10/93 01/10/94
3 classes depending on
vehicle weight : Class 1 < 1250 kg Class 2 : 1250/1700 kg Class 3 > 1700 kg
01/96 01/97
With oxygen sensor and reinforced catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.
97
INJECTION
ALL TYPES
STANDARD E.E.C. PSA A-S RP Engines Vehicles Utility vehicles : < 3.5 tonnes Class 1 : new models existing models Class 2/3 : new models existing models
EMISSION STANDARDS
APPLICATIONS Applicable Brussels directive 96/69 NOTES CHARACTERISTICS
INJECTION
3 classes depending on
01/97 10/97 01/98 10/98 vehicle weight : Class 1 < 1250 kg Class 2 : 1250/1700 kg Class 2 : 1 700 kg
With oxygen sensor and reinforced catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.
01/2000 01/2001
Brussels directive 98/69 EURO 2 standard (L3) made stricter Fiscal incentives
With 2 oxygen sensors and catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.With EOBD on-board diagnosis.
98
EMISSION STANDARDS
STANDARD E.E.C. PSA A-S RP Engines APPLICATIONS Vehicles Utility vehicles : < 3.5 tonnes Class 1 : new models existing models Class 2/3 : new models existing models Applicable Brussels directive 98/69 EURO 2 standard (L3 made stricter Fiscal incentives 3 classes depending on vehicle weight : Class 1 < 1305 kg Class 2 : 1305/1760 kg Class 2 : 1760 kg Brussels directive 98/69 EURO 3 standard (L4) ) NOTES
ALL TYPES
CHARACTERISTICS
With 2 oxygen sensors and catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles. With EOBD on-board diagnosis.
Private vehicles : All Types EURO 4 IF/ L5 Petrol new models existing models
01/2001 01/2003
made stricter
With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis.
Fiscal incentives
99
INJECTION
ALL TYPES
STANDARD E.E.C. PSA A-S RP Engines Vehicles Private vehicles : All types new models existing models
EMISSION STANDARDS
APPLICATIONS Applicable With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis. NOTES CHARACTERISTICS
EURO 4
IF / L5
01/2005 01/2006
Brussels Directive: 2001/1 EURO 3 standard (L4) made stricter Fiscal incentives
INJECTION
EURO 4 IF / L5
Petrol Gas
Utility vehicles : < 3.5 tonnes Class 1 : new models existing models Class 2/3 : new models existing models
Brussels Directives: 99/102 et 2001/1 (Gas) EURO 3 standard (L4) made stricter Fiscal incentives 3 classes depending on vehicle weight : Class 1 < 1305 kg Class 2 : 1305/1760 kg Class 3 : 1760 kg
With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis.
100
C5 - All Types
Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts. High pressure fuel pump. Do not separate the following components from the high pressure fuel pump (5) : - Sealing ring (b) (no replacement parts). - High pressure outlet connector (a) (will cause a malfunction). HDi = High pressure Diesel injection
B1HP19LC
101
INJECTION
C5 - All Types
Do not separate the following components from the diesel injector carrier (2) : - Diesel injector (e) (no replacement parts). - Electromagnetic element (c) (no replacement parts).
Do not alter the position of the nut (d) (malfunction). Do not separate the connector (f) from a diesel injector. It is forbidden to clean the carbon deposits from the diesel injector nozzle.
102
C5 - All Types
Safety requirements. IMPERATIVE : Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect the requirements below : - No smoking in proximity to the high pressure circuit when work is being carried out. - Avoid working close to flame or sparks. Engine running : - Do not work on the high pressure fuel circuit. - Always stay clear of the trajectory of any possible jet of fuel, which could cause serious injuries. - Do not place your hand close to any leak in the high pressure fuel circuit. After the engine has stopped, wait 30 seconds before any intervention. NOTE : This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure.
103
INJECTION
SAFETY REQUIREMENTS Preamble. All interventions on the injection system must be carried out to conform with the following requirements and regulations : - Competent health authorities. - Accident prevention. - Environmental protection. WARNING : Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken.
C5 - All Types
CLEANLINESS REQUIREMENTS. Preliminary operations IMPERATIVE : The technician should wear clean overalls. Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components : (refer to corresponding procedures). - Fuel filter. - High pressure fuel pump. - Third piston deactivator. - High pressure regulator. - High pressure sensor. - High pressure fuel injection common rail. - High pressure fuel pipes - Diesel injector carriers. IMPERATIVE : After dismantling, immediately block the apertures of the sensitive components with plugs, to avoid the entry of impurities. Work area. - The work area must be clean and free of clutter. - Components being worked on must be protected from dust contamination. INJECTION
104
C5 - All Types
Connect the tool [1] between the booster pump and the fuel filter (white mark at "a" on the fuel supply pipe). Connect the tool [2] downstream of the diesel injectors, between the high pressure fuel pump and the fuel filter (green mark at "b" on the fuel return pipe. Engine : 4HX WARNING : Any check of pressure downstream of the fuel filter is PROHIBITED. NOTE : To check the pressures while the vehicle is being driven, insert tool [4] between tool [3] and tools [1] et [2]. Checks on pressure : static. - Switch on ignition - For 3 seconds (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 2.6 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.6 0.4 Bar.
B1BP20JD B1BP27BD
105
INJECTION
: : : :
Kit 4073-T
C5 - All Types
Checks on pressure : dynamic. Engine running, at idle (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 2 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.8 0.4 Bar. Abnormal functioning Fuel supply pressure Between 3.3 and 4 Bar More than 4 Bar More than 4 Bar Between 0.8 and 1.5 Bar Fuel return pressure 0.8 0.4 Bar Less than 0.8 Bar More than 0.8 Bar Less than 0.8 Bar Checks Check the condition of the diesel filter Check the low pressure regulator incorporated in the filter (locked shut) : replace. Check the fuel return circuit (pipe pinched or trapped.......). Check the fuel suppy circuit : - Booster pump (low pressure), piping.
INJECTION
Impossible to start the engine : Fuel supply pressure less than 0.8 Bar : - Check the low pressure regulator incorporated in the filter (locked open) - Check the high pressure pump distribution valve (locked shut) Check : The flow should be drop by drop Excessive fuel return
Check : diesel injector return flow. (Table below) Uncouple the diesel injector return pipe. Observe : Diesel injector functioning correctly Diesel injector locked shut.
106
C5 - All Types
(2) Flowmeter (3) Water / recycled gas exchanger (4) EGR valve (5) Turbocharger (6) Air butterfly
SIEMENS VALEO PURFLUX KKK K03 MAGNETI MARELLI 48W7 Ref. 648
B1HP1A6D
107
INJECTION
PSA 7899
C5 - All Types
VALEO. KKK K03. PURFLUX. MAGNETI MARELLI 48W7 Ref. 648. PSA 7899. NIPPON DENSO.
108
C5 - All Types
(1) Air / air exchanger (2) Air / water exchanger (3) Warm air metering device (4) Cold air metering device (5) Turbocharger (6) Flowmeter (7) Air filter BOSCH. BOSCH. ALLIEDSIGNAL GT1549P. SIEMENS. PSA 7885. INJECTION
B1HP1BYP
109
C5 - All Types
ESSENTIAL : Respect the safety and cleanliness recommendations. Tool. [1] Manual vacuum pump: FACOMM DA 16.
INJECTION
B1HP1ARP
Checks. ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure diesel injection (HDi) engines.
110
C5 - All Types
INJECTION
C5 - All Types
INJECTION
B1HP1BVD
ESSENTIAL : Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines. EGR electrovalve - Check, not under load, between the electrovalve (4) and the EGR valve (2). - Connect the tool [1] between the electrovalve (3) and the butterfly housing (1). - Compare readings with the values in the table below. Butterfly housing electrovalve. - Check, not under load, between the electrovalve (3) and the butterfly housing (1). - Connect the tool [1] between the electrovalve (3) and the butterfly housing (1). - Compare readings with the values in the table below. Engine speed (rpm) 780 2500 112 Vacuum value (bar) 0.5 Bar 0 Bar
C5 - All Types
EGR valve - Connect tool [1] on the EGR valve capsule take-off (2). - Apply a vacuum of approx. 0.6 bar to activate the EGR valve. - In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating. - Repeat the operation several times. INJECTION
Butterfly housing - Remove the air duct between the air/air exchanger and the butterfly housing (5), (1). - Connect tool [1] on the butterfly housing vacuum capsule (1). - Apply a vacuum of approx. 0.8 bar, the flap (a) of the butterfly housing (1) should be closed.
B1HP1BWC B1BP2ADC
113
C5 - All Types
ESSENTIAL : Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines. Electrovanne (EGR). - Check, not under load, between the electrovalve (3) (blue connector) and the EGR valve (2) (tube with blue marking). - Connect the tool [1] between the electrovalve (3) and the EGR valve (2). - Compare readings with the values in the table below. Butterfly housing electrovalve - Check, not under load, between the electrovalve (4) (black connector) and the butterfly housing (1) (Metering pump cold), (tube with white marking). - Connect the tool [1] between the electrovalve (4) and the butterfly housing (1). - Compare readings with the values in the table below. Engine speed (rpm) 780 2500
B1HP1B8D
INJECTION
114
C5 - All Types
- Connect tool [1] on the take-off (a) of the EGR valve capsule (2). - Apply a vacuum of approx. 0.6 bar to activate the EGR valve. - In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating. - Repeat the operation several times.
Butterfly housing - Remove the air duct between the air/air exchanger and the butterfly housing (1). - Disconnect the tube (white marking) on the electrovalve (4) (black connector). - Connect tool [1] on the tube with the white marking. - Apply a vacuum of approx. 0.8 bar, the flap (b) of the butterfly housing (1) should be closed.
B1BP29NC
B1BP29PC
115
INJECTION
EGR valve
C5 - All Types
Engine : RHY
116
C5 - All Types
- Start the engine. - Engage first gear and start the vehicle. - Engage the gears up to third gear. - Decelerate to 2000 rpm. - Gradually accelerate. - Check the pressure : 0.95 0.05 Bar - Remove the tools [1] and [2] Refit: - The sleeve. - The collars (3). - Tighten the collars (3).
C5FP0ACC
117
INJECTION
ESSENTIAL : Observe the following checking requirements : - Engine at running temperature. - Vehicle in running order. - Engine at full load.
C5 - All Types
INJECTION
Checks. ESSENTIAL : Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines. Preliminary operations. Carry out the following operations: Remove the screw (1). Disconnect the tube (2). Move aside the pressure sensor (3). Preparation of tools : in position on the vehicle. Fit as follows : Remove the hose (a) of tool [5], screw in its place the tool [3], remove the hose (b) of tool [5], screw the hose (b) of tool [5] on the pressure gauge [1], screw the adaptor [4] onto the tool [5]. Connect the tube (2) of the pressure sensor (3) on the tool [4], tighten the tube (2) with a Serflex type collar.
B1BP28DC E5AP1SUC
118
C5 - All Types
B1BP28EC
C5FPOBLC
119
INJECTION
C5 - All Types
Emission standard Equipment INJECTION C5 DW 10 RHY
RHS
RHZ
120
SYNERGIE
SYNERGIE
DW
10
RHZ
CP1 (*)
121
INJECTION
SYNERGIE
16/11/98
INJECTION
B1HP16PC
Reminder : RHY and RHZ are equipped with 4 diesel injector carriers marked according to their injection duct diameters (flow of diesel fuel). Identification. The injector carriers have an engraving or paint mark on the upper part of the coil, close to the diesel fuel return aperture : Mark 1 = BLUE paint mark = Injector class 1. Mark 2 = GREEN paint mark = Injector class 2. Identification marking: a : Supplier identification. b : PSA identification no. c : Identification of class. After Sales operations. ESSENTIAL : When changing a diesel injector carrier, order a component of the same class.
# 15/11/98 (RPO No.) (injector carrier without marking), always order a class 2 injector carrier.
122
SPARKING PLUGS
Vehicles - Models 1.8I 16V C5 2.0i 16v 2.0i HPi 3.0i 24S SYNERGIE 2.0i 16v Engine type 6FZ RFN RLZ XFX RFN BOSCH CHAMPION EYQUEM
SYNERGIE - C5
Electrode gap Tightening torque (m.daN)
REC94CL
RFN52HZ 1 mm
2.75 0.2
123
ALLUMAGE
ALL TYPES
SPEEDOMETER
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates : - The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed SD and the speed travelled ST, there must always be the following relationship :
CLUTCH SPECIFICATIONS
Petrol 1.8i 16V Engine type Gearbox type Supplier Mechanism / type Clutch disc of lining. Ext/Int Quality of lining F 808 F 410 11 R 10X 230 DNG 4700 12 R 14X 228/155 F 808 DS 6FZ BE4/5 VALEO 230 DING 4700 228 D 73 12 R 14 X 230 DNG 4700 R 11 R 14X 242 T 6500 11 A 14X 242/162 F 410 2.0i 16V RFN 2.0 HPi RLZ ML/5 3.0i V6 XFX
125
CLUTCH SPECIFICATIONS
Diesel 2.0 HDi Engine type Gearbox type Supplier Mechanism / type Clutch disc of lining. Ext/Int Quality of lining 228/155 F 408 225/150 F 808 230 P 4700 225 T 5700 RHY BE4/5 LUK 242 T 6500 Damping performed by engine flywheel 242/162 RHS RHZ ML/5 2.2 HDi 4HX
126
C5 - All Types
Gear controls
Gear engagement ball-joint 10 mm. Gear control lever Gear engagement control cable. Gear selection control cable. Cable selection locking ley. Gear selection ball-joint 10 mm. CLUTCH GEARBOX DRIVESHAFTS
B2CP3CJD
127
C5 - All Types
Gear selection control cable.
B2CP3CKD
B2CP3CLD
Left hand drive Length A Length B Note : See adjustment - page 129. CLUTCH GEARBOX DRIVESHAFTS
128
C5 - All Types
Adjustments. WARNING : Control cables should be adjusted each time the gearbox is removed or cables changed.
WARNING : Do not use oil to detach the ball-joints. To release the ball-joint, press at the centre a then pull the ball-joint upwards. Ball-joints alone can be changed by removing the unlocking key with the aid of two thin screwdrivers, unclip at b. To unlock the ball-joint, turn in the direction of the arrow c. CLUTCH GEARBOX DRIVESHAFTS
B2CP3CVD
B2CP3CWC
B2CP3CXC
129
C5 - All Types
Tools. [1] Tool for positioning the gearbox control lever 8605-T Toolkit 9040-T
Adjustments. Cables should be adjusted each time the gearbox, gear controls or power unit are removed Adjustment principles : - Lock the gear lever in neutral position, using tool [1]. - Position the gearbox in neutral. - Anchor the ball-joints on the gearbox levers. - Lock the cable lengths with the ball-joint locking keys. Inside the vehicle. - Remove the central console (See corresponding operation). - Remove the plastic blank at (a). - Insert tool [1] fully and rotate a quarter turn to lock the gear control lever. - At neutral.
B2CP3E7C
130
C5 - All Types
Adjustments (continued) Under the bonnet. - Remove the air filter assembly. - Unlock the gear engagement cable ball-joint (b). - Unlock the gear selection cable ball-joint (c). - Make sure the gear levers (engagement and selection) are in neutral position. - Lock the cable lengths with the ball-joint locking keys. - Remove the tool [1]. Checks. Remove the tool [1]. Check that all the gears engage without tightness. Check that the gear lever moves identically forwards and backwards and to right and left. If not : Repeat the adjustment.
131
C5 - All Types
8605-T.
engagement ball-joint 10 mm. control lever engagement control cable. selection control cable. selection ball-joint 10 mm.
B2CP3CQD
132
C5 - All Types
B2CP3CRD
B2CP3CSD
Left hand drive Length A Length B Note : See adjustment - page 134.
133
C5 - All Types
Adjustments.
WARNING : Control cables should be adjusted each time the gearbox is removed or cables changed.
WARNING : Do not use oil to detach the ball-joints. To release the ball-joint, press at the centre a then pull the ball-joint upwards. Ball-joints alone can be changed by removing the unlocking key with the aid of two thin screwdrivers, unclip at b.
B2CP3CTD
B2CP3BYC
134
C5 - All Types
Toolkit 9040-T
Cables should be adjusted each time the gearbox, gear controls or power unit are removed. Adjustment principles : - Lock the gear lever in neutral position, using tool [1]. - Position the gearbox in neutral. - Anchor the ball-joints on the gearbox levers. - Lock the cable lengths with the ball-joint locking keys. Inside the vehicle. - Remove the central console (See corresponding operation). - Remove the plastic blank at (a). - Insert tool [1] fully and rotate a quarter turn to lock the gear control lever. - At neutral.
B2CP3E7C
135
C5 - All Types
Adjustments (continued) Under the bonnet. Remove the air filter assembly. Unlock the gear engagement and selection cable ball-joint (b). Make sure the gear levers (engagement and selection) are in neutral position. Lock the cable lengths with the ball-joint locking keys. Remove the tool [1].
Checks. Remove the tool [1]. Check that all the gears engage without tightness . Check that the gear lever moves identically forwards and backwards and to right and left. If not : Repeat the adjustment. Refit the console and the air filter assembly.
B2CP3EBC
136
SYNERGIE
(1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (4) Gear selection ball-joint 10 mm. (5) Gear engagement ball-joint 10 mm. (6) Flexible insulating grommet through the bulkhead.
B2CP3BWD
137
SYNERGIE
Principles. Lock the gear lever in neutral position, using tool: 9607-T. Place the gearbox in neutral. Couple the cables on the lever. Fit the ball-joints on the gearbox lever. Lock the cable lengths with the ball-joint locking keys. CLUTCH GEARBOX DRIVESHAFTS
WARNING : Do not use any tool to unclip the ball-joints. To unlock the ball-joint, press at the centre a, then pull the ball-joint upwards.
NOTE : Changing an individual ball-joint is possible as long as the locking key is removed. Unclip at b, using two small screwdrivers.
B2CP3BXC
B2CP3BYC
138
SYNERGIE
: 9607-T. CHECKS. - Remove the tool [1]. - Check that all the gears engage without tightness . - Check that the gear lever moves identically forwards and backwards and to right and left. If it does not, repeat the adjustment. - Refit the trim under the gear lever. - Refit the air filter assembly.
B2CP3C6C
B2CP3C0C
139
SYNERGIE
Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system)
B2BP03EC
140
SYNERGIE
B2BP02SC
NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable. DESCRIPTION 5 - Tensioning spring ensuring the maximum length of the outer cable. 6 - Wear take up device. 7 - Attaching end-piece.
1 2 3 4
Metallic cable, crimped on both ends. Outer cable or telescopic duct. Outer cable stop, bulkhead side (fixed point on the bodyshell). Outer cable stop, gearbox side (fixed point on the gearbox).
141
SYNERGIE
B2BP03QD
Operation For the adjusting device to operate correctly, it is necessary that : The pedal is at rest (against its upper stop) The locking sleeve (1) is slightly compressed, the rollers (2) are free, the outer cable (3) length may vary.
Clutch disengagement phase As soon as the pedal is applied, the attaching end-piece (4) leaves the sleeve (1) which moves back. The rollers, pushed by spring (5) jam the system. The cable behaves like a conventional cable.
Engagement / adjustment phase The pedal returns to rest on its upper stop. Attaching end-piece (4) pushes sleeve (1) which frees the rollers. Outer cable (3), kept extended by the spring (6) becomes : - Shorter if the clutch disc is worn. - Longer if the outer cable has been compressed.
SYNERGIE
B2BP03RC
E5AP14VC B2BP03SC
SYNERGIE
B2BP03ZD
144
SYNERGIE
B2BP03ZD
145
After fitting on the vehicle, the circuit should be filled with a DOT 4 type brake fluid. Clutch control reservoir capacity 120 cc. (Bleeding is carried out not under pressure). Repair. The new clutch control components are not compatible with the old parts. Both the old and the new components are marketed by Replacement Parts . Draining Filling - Top-up. - Check the level after each repair visit. - Fill the circuit (after drainage), using a filling cylinder specifically designed for this operation. - Use the circuits bleed screw (7). - The level of fluid inside the clutch control reservoir should be between the min. and max. marks. NOTE : Wear on the clutch causes a slight increase in the level of fluid inside the control reservoir.
SYNERGIE
B2CP16FP
146
C5 - All Types
2.0 HPi RLZ
ML/5T
4 HP 20
C5 - All Types
Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio
RHY
Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio CLUTCH GEARBOX DRIVESHAFTS
SYNERGIE
Diesel 2.0 HDi RHY ML/5 20 LE 91 (*) 15x67 25x20
149
SYNERGIE - C5
BE4/5 GEARBOX
Engine : RFN
(a) Marking zone (sequence and serial no.). (b) Location of identification label.
B2CP3BNC
B2CP3BPD
150
BE4/5 GEARBOX
Engine : RFN Description (1) Primary shaft. (2) Clutch bearing guide. (3) Gearbox casing. (4) Clutch housing. (5) Reverse idle. (6) Drive gear (3rd gear). (7) 3rd /4th gear synchroniser (8) Drive gear (4th gear). (9) Drive gear (5th gear). (10) 5th gear synchroniser. (11) Driven gear (5th gear). (12) Driven gear (2nd / 4th gear ) (13) Driven gear (2nd gear).
SYNERGIE - C5
1st / 2nd gear synchroniser Driven gear (1st gear). Secondary shaft. Differential gear. Satellite gears. Planet gears. Differential housing. Speedometer drive. Extension.
d Adjusting shims : 0,7 to 2,4 mm. (From 0,10 to 0,10 mm) c Adjusting shims : 1,4 to 1,6 mm. (From 0,10 to 0,10 mm) CLUTCH GEARBOX DRIVESHAFTS
B2CP3BQP
151
SYNERGIE - C5
BE4/5 GEARBOX
Engine : RFN Tightening torques Ref. 1 2 3 4 5
B2CP3BSP
Description End guide Clutch housing Primary shaft nut Secondary shaft nut Yoke holding screw Differential gearwheel screw Reverse gear contact
Number of screws 3 13 1 1 2 2 1 4 1 7 1 4 1
m.daN 1.2 0.1 1.3 0.1 7.2 0.7 6.5 0.7 1.5 0.1 6.5 0.7 2.5 0.3 5 0.5 1.7 0.2 1.2 0.1 2.2 0.2 1.2 0.1 3.5 0.4
Differential housing Breather pipe Rear housing cover screw Top-up plug Differential housing screw Drain plug screw 152
12
C5 - All Types
Identification
(a) Marking zone (Sequence and serial no.). (b) Location of identification label.
B2CP3CMC
153
C5 - All Types
(25) Clutch bearing guide (26) Secondary shaft nut (27) Differential screw
B2CP3CNP
154
C5 - All Types
Reverse lamp switch Gearbox casing /clutch housing fixing screws Differential bearing stop plate screws Gearbox rear casing screws Drain plug Filling / top-up plug M8 screw (Differential housing fixing) M10 screw (Differential housing fixing) Selector guide screw
2,5 0,2 2 0,2 2 0,2 2 0,2 3 0,3 3 0,3 2 0,2 4 0,5 4 0.5 CLUTCH GEARBOX DRIVESHAFTS
B2CP3CPD
155
C5 - All Types
= 1.8 litres
B2CP3CUC
156
C5 - All Types
B2CP3CYD
157
C5 - All Types
Tightening torques m.daN. Gearbox exterior. (2) (3) (4) (5) (6) (7) (8) Oil channel union fixing Exteror fixing of Exterior fixing of converter cover on clutch housing Speedometer take-off aperture plug Steel casing fixing Converter fixing on engine Interior fixing of converter cover on clutch housing Torx fixing of converter cover on clutch housing 2.5 0.5 2.3 0.5 1 0.1 0.6 0.1 61 2.3 0.5 2.3 0.5 4.5 0.8 3.5 0.5 1 0.2 6.5 1 5.8 1
Drain plug Heat exchanger fixing Selector lever position switch fixing Converter cover fixing on engine cover (XFX engine) Converter cover fixing on engine cover (4HX engine)
B2CP3CZC
B2CP24BC
B2CP24CC
158
C5 - All Types
Gearbox interior. (9) Input speed sensor fixing (10) Hydraulic block fixing (Large head) (11) Output speed sensor fixing 0.8 0.1 0.8 0.1 1 0.2
B2CP24DC
B2CP24EC
159
C5 - All Types
Towing. The front of the vehicle must be raised in order to be towed. If the front of the vehicle cannot be raised : IMPERATIVE : - Put gear lever in position N. - Do not add any oil. AL4 gearbox - Do not exceed 50 km/h (30mph) over a distance of 50 km (30m). 4 HP 20 gearbox - Do not exceed 70 km/h (45mph) over a distance of 100 km (60m). Driving. Never drive with the ignition switched off. Never push the vehicle to try to start it; (impossible with an automatic gearbox). Lubrication The automatic gearbox is only lubricated when the engine is running.
REMOVING - REFITTING. (Automatic gearbox). WARNING : Never place the gearbox on its lower casing (risk of deforming the tray and damaging the hydraulic valve block). Never use the connections as handles for raising, turning, holding or pushing the gearbox. ESSENTIAL : - Fit the converter retaining peg while the gearbox is removed. - Fit the centring peg to locate the gearbox on the engine: (remove the converter retaining peg just before locating) WARNING : With the emergency programme selected, an impact is felt when changing from P R ou N R.
160
C5 - All Types
161
Oil level. See corresponding operation. An excessive oil level can result in the following consequences : - Excessive heating of the oil. - Oil leaks. An insufficent level causes the destruction of the gearbox. Top up the level of oil in the gearbox (if necessary). Check using a diagnostic tool. Read the fault codes (engine and gearbox). Absence of fault codes. Carry out parameter measures, actuator tests and a road test. Presence of fault codes. Carry out the necessary repairs. Delete the fault codes. Carry out a road test to check the repair and, if need be, modify the gearbox ECU parameters (this is essential after an initialisation of the ECU).
C5 - All Types
When the ECU detects an erroneous or non-existent value on input or output : - It writes the fault in memory. - For each associated context, it writes the context of the oldest fault in memory. - It initiates a back-up mode strategy. There are two types of back-up modes : - The ECU makes replacement values available (relating to comfort, gear selection quality, loss of functions). - Access to emergency programme (only 3rd ratio and reverse are available) NOTE : 4 HP 20 : A snatching may be felt when changing : P/R - N/R - N/D. CLUTCH GEARBOX DRIVESHAFTS
Reading the fault codes. Read the fault codes. No fault codes present : Carry out a measure of parameters. Anomalies present : YES : Carry out the necessary repairs. NO : Read the fault codes engine ECU - Carry out a road test. Following an initialisation of the ECU, for a certain period of time there may be an inconsistent gear selection quality (while ECU parameters are adapted to the gearbox). To achieve a consistent standard, it is necessary to carry out a road test taking in frequent gear changes (auto-adaptive laws).
162
C5 - All Types
IMPERATIVE : Every update of the automatic gearbox ECU must be accompanied by an update of the engine ECU.
163
C5 - All Types
Downloading (AL 4 only). ECU downloading procedure : - Follow the diagnostic tooling procedure. A new ECU or downloaded update is always configured with the following options : - SHIFT LOCK gear selection lever position. - OBD outlet (emission standard L4). If the ECU is to be fitted to a vehicle without one or both of these options: - Carry out a configuration which inhibits the diagnosis of the option(s) concerned. CLUTCH GEARBOX DRIVESHAFTS
Pedal initialisation. (AL 4 only). A pedal initialisation must be carried out in the following cases : - Replacement of the automatic gearbox ECU. - Replacement of the automatic gearbox. - Downloading of the ECU configuration. - Adjustment or replacement of the accelerator cable. - Replacement of the throttle potentiometer.
- IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistent gear selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes (auto adaptive laws).
164
C5 - All Types
165
4 HP 20 GEARBOX CONTROLS
Engines : XFX - 4HX Selection control. The gear selection control has 5 positions. The selection lever is guided by the shape of the stepped gate and by a retaining spring which holds it towards the left. The gear selection control is equipped with the shift lock, so you have to switch on the ignition and apply the brake pedal to unlock the selection lever from the park position. Selection (P) : Park (locking and immobilisation of the vehicle). Selection (R) : Reverse gear. Selection (N) : Neutral. Selection (D) : Drive (Use of the four gears in their autoadaptive automatic function) Selection (M) : Manual (M + M -) allowing the driver to select gears by pulling and pushing the gear lever. In position M, selection is by an electronic sensor located close to the gear lever. The variation of flux necessary to the movement of the sensor cells is obtained by a magnet located on the lever itself. This enables the change of status.
B2CP3DKD
166
4 HP 20 GEARBOX CONTROLS
Engines : XFX - 4HX Selection control (continued).
C5 - All Types
In position M, selection is by an electronic sensor located close to the gear lever. The variation of flux necessary to the movement of the sensor cells is obtained by a magnet located on the lever itself. This enables the change of status. The information is transmitted to the gearbox ECU. Two switches placed on the gear control gate permit the driver to choose one of the following three driving programmes: - Normal : The normal programme operates in the absence of the other two (Eco law, autoadaptative mode). - Sport : Permits a more dynamic, sporty performance. - Snow : Facilitates starting and adhesion on slippery surfaces. To return to the normal programme, press a second time on the sport switch or snow switch. Only when the selector is in position (P) or (N) can the engine be started. - (1) Control linkage with ball-joint. - (2) Automatic adjustment (Push-button c , pressed in to lock the control adjustment, springs out for the adjustment to be made). - (3) Cable sleeve stop. The automatic gearbox is controlled by cable.
B3CP3DLC
167
SYNERGIE
B2CP3CFD
168
DRIVESHAFTS - GEARBOX
Tightening torques (m.daN) Vehicles Gearbox BE4/5 C5 SYNERGIE ML/5 AL4 4 HP20 Engines 6FZ - RFN - RLZ RHY XFX RHZ - 4HX 6FZ - RFN - RHZ XFX - 4HX Driveshaft bearing Driveshaft nut
SYNERGIE - C5
Gearbox oil seal mandrels Right 7114-T.W 9017-T.C Left 7114-T.X 5701-T.A 0338 H1 0338 H2 8010-T.J 8010-T.K2 Tool kit 7116-T 9017-T 0338 8010-T
2 0.2
Steel Aluminium
9 0.5 10 0.5
C5 - All Types
Measuring front height The measurement of the front dimension H1 is between ground level and the measuring zone on the front subframe (to the rear of the front yokes fixing the suspension arm).
AXLE GEOMETRY
Measuring rear height
B3BP166D
B3BP168D
L1 (mm) Theoretical dimension between the level of the front subframe and the wheel axis. 140
L2 (mm) Theoretical dimension between the measuring zone on the crossmember support and the wheel axis. 73 170
AXLE GEOMETRY
Front axle Vhicle Tracking Adjustable All Types 0 to - 3 mm 0 to - 0 27' 3 03' 30' Castor Camber Non adjustable 0 30' 12 56' 30' King pin inclination Tracking Adjustable 5.4 1.3 mm 0 49 0 12 Rear axle
C5 - All Types
+= =
TOE-IN TOE-OUT
171
C5 - All Types
FRONT AXLE
Tightening torques m.daN. (1) Suspension leg upper fixing (2) Suspension leg fixing on bodyshell (3) Anti-roll bar link rod upper fixing (4) Anti-roll bar link rod upper fixing (5) Ball-joint fixing (6) Ball-joint fixing on pivot (7) Suspension leg upper fixing on pivot (8) Hub nut (9) Wheel fixing (10) Arm front fixing (11) Arm rear fixing (12) Anti-roll bar bearing fixing on subframe Stabiliser bar fixing on subframe Anti-roll bar Engines All types (except ES9J4) ES9J4 Diameter (mm) 23.5 24.5 Colour ref. Yellow White 7 0.7 4.3 0.6 6.4 0.6 6.4 0.6 4.5 0.4 25 2.5 5.4 0.5 32.5 2.6 91 13 1.3 8 0.8 4.2 0.6 6.6 0.6
B3CP05VP
B3CP05WD
NOTE : The geometry specifications are given with the suspension specifications. 172
REAR AXLE
Tightening torques m.daN. (1) (2) (3) (4) (5) (6) (7) Anti-roll bar fixing Rear rubber mounting fixing on bodyshell Rear subframe fixing Front subframe fixing on bodyshell Suspension shaft fixing Hub nut Wheel fixing
C5 - All Types
13.1 1.4 8 1.2 11.5 1.1 11.5 1.1 14.9 1.3 25 2.5 91
NOTE : (3) and (4) Face and threads not greased. Anti-roll bar Engines All types (except ES9J4) ES9J4 All types estates Diameter (mm) 21.5 22 Colour ref. Blue Yellow
NOTE : The geometry specifications are given with the suspension specifications.
B3DP08BD B3DP08CD
173
C5 - All Types
SUSPENSION
Front suspension
Tightening torques m.daN. (10) Arm front fixing 11) Arm rear fixing (12) Anti-roll bar bearing fixing on subframe 13 1.3 8 0.8 4.2 0.6
Hydractive 3+ hydraulic suspension (power steering) Suspension piston diameter Anti-roll bar diameter Anti-roll bar colour reference Suspension leg. Bump stop, height
B3CP05WD B3BP167D
"A" = 97 mm.
174
SUSPENSION
Rear suspension Tightening torques m.daN. (13) Subframe rear fixing (14) Rear rubber mounting fixing on bodyshell (15) Anti-roll bar fixing (16) Front fixing of subframe on bodyshell NOTE : (13) and (16) Face and threads greased. (17)Arm shaft fixing (18) Hub nut (19) Wheel fixing Stabiliser bar fixing on subframe Hydractive 3+ hydraulic suspension (power steering) Suspension piston diameter = 37 mm. Anti-roll bar diameter - Saloon = 21.5 mm - Break = 22 mm. Anti-roll bar colour reference - Saloon = Blue - Estate = Green
B3DP08ND B3DP08PD
11.5 1.1 8 1.2 13.1 1.4 11.5 1.1 14.9 1.3 25 2.5 91 6.6 0.6
175
C5 - All Types
SUSPENSION
Height control
B3CP06TD
176
AXLE GEOMETRY
Front axle Vhicle Tracking (Adjustable ) All Types 0 to - 3 mm 0 to - 0 27' 3 03' 30' Castor Camber (Non adjustable) 0 30' 12 56' 30' King pin inclination Tracking (Non adjustable) 5.4 1.3 mm 0 49 0 12 Rear axle
C5 - All Types
+= =
TOE-IN TOE-OUT
177
C5 - All Types
(1) Steering wheel fixing (2) Column fixing on mounting (3) Column fixing on mounting (4) Cardan fixing (5) Ball-joint fixing on pivot (6) Link rod lock nut (7) Valve fixing on cover (8) Piping fixing on ram (9) Mechanism fixing on subframe (10) Steering rack ball-joint
2 0,3 2.3 0.4 2.3 0.2 2.3 0.3 3.5 0.6 6 0,4 2.3 0.1 0.8 0.8 8 0.9 9 0.9
B3EP124D
B3EP125D
178
C5 - All Types
Angle of lock Inner 39.74 34.29 Outer 35.65 31.58 Pulley diameter 129 mm
50.4/1
Tightening torques m.daN Engine types EW-DW (12) Screw (13) Screw (14) Screw 2.2 0.3
Engine XFX : A converter, integral with the valve, modulates the assistance according to the vehicle speed. Length of steering rods (Adjustment) between ball-joints = 362 mm. Power-assisted steering hydraulic circuit. The oil supplies both the steering circuit and the suspension circuit.
B3EP127D
Petrol engine : A power-assisted steering pressure switch is installed on the hydraulic piping, between the high pressure pump and the steering valve. 179
SYNERGIE
Reference height
AXLE GEOMETRIES
NOTE A < B = Positive figure : A > B = Negative figure : Conditions for adjusting the heights (Tyre pressures correctly set) Frontt H1 158 161 166 Heights (mm) Tyres 195/70R 14 195/65R 15 205/65R 15 Rear H2 163 166 171 Camber King pin inclination 0 30 1128 40 -1 30 Tracking (Toe-in/toe-out)
+ = - =
TOE-IN TOE-OUT
B3BP051D
Rear
The reference heights must be checked between the jacking points and the ground. B3BP051D
180
FRONT AXLE
SYNERGIE
B3CP04PD
B3CP04QD
181
SYNERGIE
FRONT AXLE
Evolution : Tightening torques on front subframe 28/05/1999 #
Tightening torque. Old fitting. Tighten the screw (1) to 13.5 m.daN. Tighten the screw (2) to 13.5 m.daN. New fitting. Tighten the screw (1) to 10.7 m.daN. Tighten the screw (2) to 10.7 m.daN. NOTE : Replacement Parts markets the old as well as the new components.
B3CP055D
182
REAR AXLE
SYNERGIE
B3DP06QD
183
SYNERGIE
SUSPENSION
All Types Ft Rr Ft Rr Without air-con With air-con Ft 2 Grey = 1 Yellow Rr 3 Yellow F 23 F 254 25 30 1 Grey + 1 Yellow
Spring (ref.)
184
STEERING
Steering All Types Power-assisted Steering rack travel (mm) 152 Number of teeth Pinion 9 Steering rack 33 Number of turns of the steering wheel 2.98
SYNERGIE
Steering ratio 15.75
B3EP09ZD
185
BRAKES
C5 - All Types
1.8i 16V Engine type Master cylinder Master-vac mm Ft Caliper/piston makes Brake disc Non-ventilated Ventilated 266 22/20 ABEX 949/1 6FZ
BRAKE SPECIFICATIONS
2.0i 16V RFN 22.2 (Valve type) 254 BOSCH ZO 54/55 BIR 54 BOSCH ZO 57/56 BIR 57 283 26/24 ABEX 949/1 PSA 32 (double piston) 276 14/12 ABEX or TEXTAR 949/1 or T 4110 186 BOSCH ZO 57/28BIR 57 288 28/26 TEXTAR T 4110 2.0 HPi RLZ 3.0i V6 XFX
Disc thickness/min. thickness Brake pad grade mm Rr Cylinder or caliper Drum / max. Brake disc Non-ventilated
BRAKE SPECIFICATIONS
2.0 HDi Engine type Master cylinder Master-vac mm Ft Caliper/piston makes Brake disc Non-ventilated Ventilated 283 26/24 TEXTAR T 4110 PSA - 32 (Double piston) 276 14/12 TEXTAR or ABEX T 4110 or 949/1 187 288 28/26 BOSCH ZO 57/26 BIR 57 RHY RHS 22.2 (Valve type) 254 BOSCH ZO 57/28 BIR 57 RHZ 2.2 HDi 4HX BRAKES
Disc thickness/min. thickness Brake pad grade mm Rr Cylinder or caliper Drum / max. Brake disc Non-ventilated
C5 - All Types
Braking circuit
BRAKE SPECIFICATIONS
Braking system specifications
- Front brakes with ventilated discs. - Rear brakes with non-ventilated discs. - Handbrake lever controlling cables acting on the front wheels. - The compensator and main brake limiter functions are assured by the ABS EBD system fitted as standard at the factory on all versions. NOTE : EBD = Electronic Brakeforce Distribution
188
BRAKE SPECIFICATIONS
Braking circuit diagram
C5 - All Types
(a) Hydraulic circuit. (b) Electrical circuit. (1) Master cylinder in tandem. (2) Braking servo. (3) Brake caliper. (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles). (5) Wheel sensor. (6) Brake fluid level sensor. (7) Hydraulic block plus ECU. (8) Stoplamp switch. (9) Instrument panel. (10) Diagnostic socket. (11) Built-in systems interface (BSI).
B3GP02HP
189
BRAKES
C5 - All Types
(7) Hydraulic block Elements Electronic ECU. BRAKES
B3FP12XC
BRAKE SPECIFICATIONS
Ref. 7 Supplier ITT - A BASR MK.60 Part No. ABS MK.60 Observations 47 way connector Alone on the hydraulic block. 2 way black connector. The sensors are inductive-type. Mounted on the pivot. Non-adjustable airgap: 0.2 to 1.5 mm. Tightening torque: 0.8 0.2 m.daN 2 way black connector. The sensors are inductive-type. Mounted on the brake caliper support. Non-adjustable airgap: 0.15 to 1.6 mm. Tightening torque: 0.8 0.2 m.daN Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles) ABS MK.60 96 371 711 80 BASK MK.60 96 371 712 80 Installed on the front LH wheelarch. 4 adjustment channels.
ITT - A
96 332 952 80
96 332 954 80
SNR
TEVES
190
BRAKE SPECIFICATIONS
Brake pedal carriage Front brake
C5 - All Types
Rear brake
B3FP130C
B3FP12YC
B3FP12ZC
Tightening torques (m.daN). (15) Fixing on bodyshell (16) Servo fixing 1.8 0.25. 2.1 0.1. (12) Caliper fixing on pivot (13) Yoke fixing on caliper 191 12 1.8 3.1 0.1 (14) Rear caliper fixing on suspension arm 7 0.7
BRAKES
C5 - All Types
HANDBRAKE (Adjustment)
Adjustment - Remove the rear ashtray from the handbrake console. - (1) Nut for adjusting the tension of the handbrake cables. - Raise and support the vehicle with the front wheels hanging free. - Check the correct routing of the brake cables under the vehicle. - Apply and release the handbrake 10 times. - Set the handbrake to the 5th notch. - Tighten the nut (1) until the front brakes are applied. - Pull the handbrake lever vigorously 4 to 5 times. - Set the handbrake to the 5th notch. - Check that the front brakes are applied. - With the handbrake released, check that the wheels can be turned freely by hand. - Lower the vehicle. - Refit the rear ashtray to the handbrake console.
BRAKES
B3FP12JD
192
C5 - All Types
B3FP139C
B3FP13AC
193
BRAKES
C5 - All Types
BRAKES
B3FP13BC AB3FP13CC
194
C5 - All Types
B3FP13DC
With the bleeding apparatus - Connect the bleeding apparatus [1] on the brake fluid reservoir (1). - Adjust the apparatus pressure to 2 Bars. For each circuit : - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the bleeding apparatus [1]. - Check the brake fluid level (Should be between DANGER level and MAXI level). - Fill if necessary with the approved and recommended synthetic brake fluid. Without the bleeding apparatus. NOTE : Two operators are necessary. For each circuit : - Apply the brake pedal to place the circuit under pressure. - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the tool [1]. NOTE : Recommence the process a second time if that is necessary. - Check the brake fluid level, (Should be between DANGER level and MAXI level). - Fill if necessary with the approved and recommended synthetic brake fluid. 195
BRAKES
196
BRAKE SPECIFICATIONS
2 0 HDi Master cylinder mm Ft Disc Disc thickness Minimum disc thickness Brake pad grade Cylinder or caliper mm Rr Drum Disc Max./ min. thickness Make Brake lining grade Compensator cut-off in Bars DON 7124 Front brake 65 Rear brake 65 197 BENDIX FN 36 20.6 255 295 10/8 Master-vac Caliper/piston makes 279 GIRLING C57 57 281 (Ventilated) 26 24 GALFER 3314 36 23.8 2.0i 16V
SYNERGIE
203 + 230 (Tandem) BRAKES GALFER 36212 Front brake 85 - Rear brake 85
SYNERGIE
BRAKES
Manual adjustment of the compensator
- Set the vehicle at reference height (see page 180). ESSENTIAL : Never alter the position of the upper nut (1). - Refit the flanged nut (2). - Fit the tool 8204-T. Drum At shim A At shim B Yellow Red Disc Blue BRAKES
B3FP10TC
- Adjust the nut (3) to allow the free passage, without play, of the red shim (B), without moving the lever (4) downwards. - Tighten the lock nut (5) without modifying the adjustment. - Remove the threaded rod at C. - Tighten the flanged nut (2) over the nut (3).
198
BRAKES (continued)
SYNERGIE
Checks and hydraulic adjustment of the compensator - Use the brake pressure checking equipment 4104-T, connect diagonally and bleed: bleed screw : Caliper 8x125 - Wheel cylinder 7x100. - Set the vehicle at setting height. BRAKES - Pressure chart : Engine : 2 0 HDi Disc Front 40 65 135 Drum Rear 40 65 86 Front 50 85 135 Engine : 2.0i 16V Disc Rear 50 85 100
- If the pressures are not correct, adjust as follows : - Refit the nut (1). - Adjust using the nut (2) to obtain the braking pressure. - Tighten the lock nut (3). - Hold the threaded rod (4). - Tighten the flanged nut (1) over the nut (2).
B3FP10UC
199
SYNERGIE
HANDBRAKE
BRAKES
B3FP10VC B3FP10WC B3FP10XC
Slacken the cables using the nut (1). - Remove the blanking plug from hole A. - Position hole A opposite the toothed wheel (adjusting mechanism). - Turn the toothed wheel using a flat screwdriver until the disc locks. - LH side upwards. - RH side downwards. - Unlock the disc by turning in the opposite direction by 6 notches.
- Position the blade B of the blanking plug perpendicular to the line passing through the centre of the disc and the centre of the hole. - Tighten nut (1) to obtain a handbrake lever travel of 4 to 5 notches. - Tighten the lock nut (2).
200
HYDRAULIC SPECIFICATIONS
Location of components (A) High pressure hydraulic circuit. (B) Low pressure hydraulic circuit. (C) Electric circuit. (21) Built-in Hydro-electronic Interface (BHI). (22) Front slimline sphere. (23) Front suspension cylinder. (24) Rear slimline sphere. (25) Rear suspension cylinder. (26) Front hydractive 3+ regulator accumulator. (27) Front hydractive 3+ regulator. (28) Rear hydractive 3+ regulator accumulator. (29) Rear hydractive 3+ regulator (30) Front height sensor. (31) Rear height sensor. (32) LDS fluid reservoir . (33) Suspension switch.
C5 - All Types
B4CP01FP
201
HYDRAULIC SYSTEM
C5 - All Types
HYDRAULIC SPECIFICATIONS
Reservoir
Function Induction
Component (BHI) Built-in Hydro-electronic Interface Power steering pump (BHI) Built-in Hydro-electronic Interface
Return
HYDRAULIC SYSTEM
B4BP01BC
Synthetic fluid TOTAL FLUIDE LDS. Capacity of the circuit 4.3 litres.
202
HYDRAULIC SPECIFICATIONS
Built-in Hydro-electronic Interface (BHI).
C5 - All Types
Reference (36)
Component Electric motor Hydraulic unit comprising : Pump with 5 axial pistons - Anti-pulse hydropneumatic accumulator A safety valve Electronic control unit 4 electrovalves: Front suspension inlet Rear suspension inlet Front suspension exhaust Rear suspension exhaust
Specifications 2350 150 rpm Throughput = 0,7 l/min at 2300 rpm Diameters of the pistons = 6,35 mm Safety valve rating = 180 Bars HYDRAULIC SYSTEM
(35)
(34)
(37)
B3BP169P
203
C5 - All Types
Hydractive 3+ regulator
HYDRAULIC SPECIFICATIONS
Hydraulic unions
HYDRAULIC SYSTEM
B4BP01CD
B4DP003D
Reference G H J 204
C5 - All Types
57
- The pressure value of this type of suspension sphere is given merely as a guide. - When checking, the value read could be higher than the nominal value. NOTE : Suspension cylinders on the same axle should be equipped with the same type of membranes. Tightening torques for these spheres : 2,7 0,5 m.daN.
205
HYDRAULIC SYSTEM
C5 - All Types
(1) Front suspension sphere. (2) Rear suspension sphere. HYDRAULIC SYSTEM
B4BP01DD
(3) Front hydractive 3+ regulator accumulator. (4) Rear hydractive 3+ regulator accumulator.
206
C5
Vehicle Engine Gearbox
STARTER MOTORS
Petrol engines Reference Class Climate H Manual U 3 T C V 1.8i 16V U C5 Automatic V 4 3 4 VC H T C VC H U 2.0HPi Manual V 4 3 T C VC
ELECTRICAL SYSTEM
CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212 208
STARTER MOTORS
Petrol engines Vehicle Engine Gearbox Reference U Manual V 2.0i 16V U C5 Automatic V 4 3 4 Class 3
C5
Climate H T C VC H T C VC H T C VC ELECTRICAL SYSTEM
2.0i 24S
All Types
R2
CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212 209
C5
Vehicle Engine Gearbox
STARTER MOTORS
Diesel engines Reference Y Z1 Manual Y C5 2.0 HDi (RHS-RHZ) Automatic Z3 6+ Z1 6 5 Class 5 6 Climate H T C VC H T C VC H T C VC
ELECTRICAL SYSTEM
CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212 210
STARTER MOTORS
Diesel engines Vehicle Engine Gearbox Reference Y Manual Z2 C5 2.2 HDi Y Automatic Z2 6+ Class
C5
Climate H T C VC H T C VC
CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212 211
ELECTRICAL SYSTEM
C5
Vehicle Engine Reference
STARTER MOTORS
Alternator reference Make VALEO Petrol 1.8i 16V 2.0i 16V 2.0 Hpi 3.0i 24S C5 X Y 2.0 HDi 2.2 HDi Z1 Z2 Z3 D8 R 27 V R2 M000T 85 381 D6 RA 661 Diesel D6 RA 109 D7 R 26 D7 R 27 A001 236 080 M001 T8 0381 M001 T8 0481 A001 111 562F U D6 RA 72 M000T 82 081 EOAL 098390 MELCO BOSCH
Table of classes of starter motors CLASS Torque C Maximum current for a speed of 1200 rpm CLASS 2 5.5 Nm I 275 A CLASS 3 6 Nm I 300 A 212 CLASS 4 10 Nm I 430 A CLASS 5 11.5 Nm I 470 A CLASS 6 11.5 Nm I 500 A
ELECTRICAL SYSTEM
STARTER MOTORS
Petrol engines Vehicle Engine Gearbox Reference U Manual V 2.0i 16V U Automatic V SYNERGIE Diesel engines Y Z1 2.0 Hdi 2.0 16V HDi Manual Y Z1 5 6 5 6 4 3 4 Class 3
SYNERGIE
Climate H T C VC H T C VC H T C VC H T C VC
CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 214 213
ELECTRICAL SYSTEM
SYNERGIE
Vehicle Engine Reference
STARTER MOTORS
Alternator reference Make VALEO Petrol 2.0I 16V U V Diesel 2.0 HDi 2.0 16V HDi Y Z1 D7 R 26 D7 R 27 M001 T8 5381 D6 RA 72 M000T8 2081 M000 T8 2081 E0AL 098 390 MELCO BOSCH
SYNERGIE
Table of classes of starter motors CLASS Torque C Maximum current for a speed of 1200 rpm CLASS 2 5.5 Nm I 275 A CLASS 3 6 Nm I 300 A 214 CLASS 4 10 Nm I 430 A CLASS 5 11.5 Nm I 470 A CLASS 6 11.5 Nm I 500 A
ELECTRICAL SYSTEM
ALTERNATORS
Class of alternator Vehicle Model Gearbox Without aircon Without Cold Pack With Cold Pack Base With GPS Base With GPS 9 With aircon Without Cold Pack With Cold Pack Base With GPS Base With GPS 12 12 12 12 9 9 9 9 12 Automatic C5 Manual 2.0i 16V 12 Automatic 12 9 CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 217 215 12 12 9 9 9 9 12 12 9 9 9 12 9 12 12 9 12
C5
Climate
12
ELECTRICAL SYSTEM
H T C VC H T C VC H T C VC H T C VC
C5
Vehicle Model Gearbox
ALTERNATORS
Class of alternator Without aircon With aircon Without Cold Pack With Cold Pack Without Cold Pack With Cold Pack Base Manual Automatic With GPS Base With GPS Base With GPS Base With GPS H T C VC H T C VC H T C VC Climate
3.0i 24V
15
15
15
15
C5
Manual
15
15
15
15
15
15
15
15
2.0 HDi
Automatic
15
15
15
15
15
15
15
15
ELECTRICAL SYSTEM
CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 217 216
ALTERNATORS
Vehicle Engine 1.8i 16V 2.0i 16V 2.0 HPi 3.0i 24S C5 2.0 HDi All types 15 2.0 HDi (1) 2.2.HDi Gearbox Class 9 12 A14 VI 25+ SG 15 S0 16 SG 15 S0 21 A14 VI 27+ SG 15 S0 18 SG 15 S0 22 A14 VI 41+ VALEO A 13 VI 204+ SG 10 B0 21 Alternator reference Make MELCO A002 TB 4891 A003 TA 0891 A004 TF 0091
C5
BOSCH
A 120 51 611
217
ELECTRICAL SYSTEM
SYNERGIE
Vehicle Model Gearbox Without aircon 8 Manual
ALTERNATORS
Class of alternator With aircon 12 9 Climate H T C VC H T C VC H T C VC
8 9
15 12
Manual
15
ELECTRICAL SYSTEM
CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page : 219 218
ALTERNATORS
Vehicle Model Gearbox Class 8 9 All types 2.0 HDi 2.0 16V HDi 12 A14 VI 40+ SG 15 S0 17 SG 15 S0 18 SG 15 S0 22 A14 VI 41+ VALEO A13 VI 2A6 SG 8 B0 21 A13 VI 277+ SG 10 B0 22 Alternator reference Make MELCO A005 TA 6391
SYNERGIE
BOSCH
A003 TB 2691
15
219
ELECTRICAL SYSTEM
ALL TYPES
2000 rpm 29 A
3000 rpm 39 A
4000 rpm 43 A
42 A
54 A
59 A
49 A
62 A
68 A
12
72 A
90 A
100 A
ELECTRICAL SYSTEM
15
D1AP01SC
99 A
128 A
140 A
220
C5 - SYNERGIE
Pre-post-heating (Pre-heating time at 20C)
C5 Synergie
CHAMPION CH 170
R 0.6
221
ELECTRICAL SYSTEM
C5 - SYNERGIE
Vehicle Engine version Date
C5
1.8i 16V-2.0i 16V 2.0 HPi 3.0i 24S 16V 2.2 HDi 2.0 HPi
650 11/2000 : + 0 - 50 gr
SD 7 V16
SD 7 V16
SP 10
DELPHI V5 (1)
265 15
PLANETELF 488
SYNERGIE
All Types
06/94 >
1000 50 gr
SD 7 V16
135
SP 10
AIR CONDITIONING
222
SYNERGIE
Tool kit 4164-T
SYNERGIE
All Types
5/8
Black
8005-T.A.
C5HP073C
Tightening torques (m.daN). Unions Aircon compressor fixings. IMPERATIVE : Tighten the front part of the compressor (timing belt end), before tightening the rear part of the compressor. Pipes M 06 M 08 M 10 Steel/Steel 1.7 0.3 3.8 0.3 4 0.3 Aluminium/Steel 1.3 0.3 2 0.2 2.5 0.3
REMINDER : Refilling the air conditioning system should be done through the LOW PRESSURE valve whenever possible. NOTE : The diameters of the High Pressure and Low Pressure valves are different, to avoid mixing them up. 223
AIR CONDITIONING
AIR CONDITIONING
C5 - SYNERGIE
Vehicle C5
SYNERGIE (*)
(*) = The (three) pollen filters on SYNERGIE are located at the base of the windscreen. 224
C5
Remove : - The trim (1) under the dashboard (drivers side). - The cover (2).
Unclip at a and pull out the pollen filter (3). Remove the pollen filter (3).
C5FP0C5C
C5FP0C6D
225
AIR CONDITIONING
AIR CONDITIONING
C5
Reminder : All repairs on an aircon circuit require the aircon circuit to be drained. After carrying out the dismantling operations necessary to gain access to the condenser, proceed to clean the area of the skirt (8) of the reservoir (6) using a cloth, then replace the dryer reservoir (6). Removing the plastic bracket holding the reservoir (6) : - Remove the screw (3) (Torx 20), from the bracket assembly/plastic counter-bracket (4) and (5). - Remove the counter-bracket (5).(Rotate it round the hinge in a clockwise direction). - Disengage the bracket from the harness (1) (Rotate it round the reservoir (6) anti-clockwise). - Remove the bracket (5) from the reservoir body (6). Unscrewing the reservoir (6). - Unscrew the reservoir (6) using the tool [2].
C5HP16EC
226
C5
Removing the reservoir (6) from the base (8). WARNING : This operation requires the greatest care, the base (8) should be kept clean prior to fitting the new reservoir. - Remove the reservoir (6) and the protection skirt (7), avoiding WITHOUT FAIL any contact or collision with other items under the bonnet (Risk of impurities entering the base (8)). - Check before refitting the reservoir (6) that the base (8) is clean. (If it is not, clean in and around the base (8) with a paper cloth.) Preparing the new dryer reservoir - Remove the black plastic protection cap from the reservoir neck (6) , leaving in place the green protection at the other end, in order to keep the new reservoir (6) sealed when mounting it in the base (8) of the condenser. - Use the grease sachet in the replacement kit, to lubricate the threads of the reservoir. - Use the oil sachet in the replacement kit, to lubricate the two O-ring seals of the reservoir (6). - Position the reservoir (6), with its new protection skirt (7) from the replacement kit, and engage the threads of the reservoir (6) in the base (8). - Check that the downward edge of the skirt (7), covers the base (8) all around it.
C5HP16EC
227
AIR CONDITIONING
AIR CONDITIONING
C5
WARNING : The reservoir (6) contains a drying agent. As soon as the black protection is removed, the reservoir must be mounted in the base (8), otherwise there is a risk of damaging the air conditioning circuit. Screwing the reservoir (6) into the base (8). - Screw the reservoir (6) manually, until the neck of the reservoir (6) is in contact with the bottom of the base (8). - Tighten with a torque spanner and tool [2] at (2) to 1.3 0,1 m.daN. Fitting the plastic bracket. (New, from the replacement parts kit). Proceed in the opposite order to removal, tighten the screw (3) to 0.15 m.daN.
C5HP16EC
228
ALL TYPES
1/ Repairing a system without leaks. a) - Using draining/recovery equipment not fitted with an oil decanter. - Drain the system as slowly as possible via the LOW PRESSURE valve, so as not to lose any oil. - No more oil should be added when filling the system with R 134.a fluid. b) - Using draining/filling equipment fitted with an oil decanter. - Drain the R 134.a fluid from the system in accordance with the instructions in the equipment handbook. - Measure the amount of oil recovered. - Add the same amount of NEW oil when filling the system with R 134.a fluid. c) - Replacing a compressor. - Remove the old compressor, drain it and measure the oil quantity. - Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor. - No more oil should be added when filling the system with R 134.a fluid.
229
AIR CONDITIONING
AIR CONDITIONING
ALL TYPES
2) Slow leak. - Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3/ Fast leak. This type of leak causes both oil loss as well as allowing air to enter the system. It is therefore necessary to : - Replace the dryer. - Drain as much oil as possible (when replacing the faulty component). Either before or during filling of the system with R 134.a fluid, introduce 80 cc of NEW oil into the system.
230
ALL TYPES
If all these conditions are met, take the following action : - Start the engine, with the air conditioning off, and wait for the cooling fan first speed to cut in. - Operate the air conditioning and set the engine speed to 2500 rpm. NOTE : If the exterior temperature reaches 40 C, the engine speed will return to 2000 rpm in order to prevent the compressor from being cut off by the High Pressure safety device (Pressostat). After the air conditioning has been on for three minutes, measure : - the exterior temperature in the workshop, - the temperature of the air coming out of the central vents. Compare the two values using the table overleaf.
231
AIR CONDITIONING
AIR CONDITIONING
SYNERGIE
Vehicle using R134.a fluid (Compressor with variable capacity) Exterior temperature in C Vehicles Temperature in C at the central vents SYNERGIE 12 3 83 40 35 30 25 20 15
(*) At exterior temperature 20C, air temperature from the central vents is for second speed of the ventilator fan. If fan operates at first speed, then air temperature from the central vents becomes 8.4 3 C. NOTE : In general, the temperature of the air being blown from the central vents should be around 5C to 8C. 232
ALL TYPES
- The temperature of the air coming out of the central vents (See the table on page 288). - The High Pressure. - The Low Pressure. Compare the values recorded with the table below, or the graphs.
Exterior temperature in C Vehicles High pressure (Bars) Low pressure (Bars) SYNERGIE
40
Vehicle using R134.a fluid (Compressor with variable capacity) 35 30 25 20 15 16 3 2.1 0.3 13 3 1.8 0.3
233
AIR CONDITIONING
AIR CONDITIONING
C5
(1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity.
(a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 0,1 m.daN (d) Condenser dryer reservoir Tighten to 1,4 0,2 m.daN.
C5HP15QP
234
C5
(1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity.
(a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 0,1 m.daN (d) Condenser dryer reservoir Tighten to 1,4 0,2 m.daN.
C5HP15RP
235
AIR CONDITIONING
AIR CONDITIONING
C5
(1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity.
(a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 0,1 m.daN (d) Condenser dryer reservoir Tighten to 1,4 0,2 m.daN.
C5HP15SP
236
C5
(1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity.
(a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 0,1 m.daN (d) Condenser dryer reservoir Tighten to 1,4 0,2 m.daN.
C5HP15TP
237
AIR CONDITIONING
AIR CONDITIONING
SYNERGIE - XU - EW10
C5HP12EC
Tightening torques. (1) (2) (3) (4) (5) High pressure valve Low pressure valve Pressostat, tighten to 1,8 m.daN Dryer Clickfit union.
C5HP15PP
SYNERGIE - DW10
C5HP12EC
High pressure valve Low pressure valve Clickfit union. Pressostat, tighten to 1,8 m.daN Flange fixing, tighten to 0,8 m.daN. Flange fixing, tighten to 0,8 m.daN. Flange fixing, tighten to 4 m.daN.
239
AIR CONDITIONING